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Received: 27 April 2020

| Revised: 25 September 2020


| Accepted: 5 October 2020

DOI: 10.1111/cote.12506

ORIGINAL ARTICLE

Understanding dispersion of copper phthalocyanine alpha blue


pigment in polyethylene masterbatch with the use of wax

Mert Yücetürk1,2 | Mehmet Özgür Seydibeyoğlu1

1
Materials Science and Engineering, Izmir
Katip Celebi University, Izmir, Cigli,
Abstract
Turkey Coloured plastics and polymers are widely used in packaging and consumer goods.
2
Budin Kimyevi Maddeler, Cigli, Izmir, Despite their critical roles, there is limited literature on detailed analysis of effective
Turkey
pigment dispersion in polymer matrices for masterbatch applications. In this study,
Correspondence detailed research was conducted on pigment dispersion using different wax materials
Mehmet Özgür Seydibeyoğlu, Materials and their performances in polyethylene masterbatches were compared. During the
Science and Engineering, Izmir Katip
study, it was first found that the presence of salt crystals plays a critical role in dis-
Celebi University, 35620, Cigli, Izmir,
Turkey. persion in one of the tested pigments. Using a laser particle size device, it was shown
Email: seydibey@gmail.com that homogeneous particle size distribution is another critical parameter for proper
pigment distribution. Although filter testing is a common method in industrial ap-
plications, there is very limited information in the academic literature. The filter test
method was used to examine the effects of different polyethylene waxes on pigment
dispersion. The best filter pressure values were obtained in masterbatches made with
micronised wax. It was also observed that the improved dispersion increased the me-
chanical properties of the masterbatch. The masterbatch colours were measured with
a sphere spectrophotometer and it was observed that uniform pigment distribution
increased the colour strengths. Similar results were also seen in polyethylene films
produced by the blown film process.

1 | IN T RO D U C T ION a wide variety of parameters such as wax type, pigment par-


ticle size, extruder screw, process temperature, mixing time,
Synthetic polymers have played a critical role in people's screw design of extruder, and other extruder parameters.1,2
lives with their wide range of applications since their discov- The number of aggregates and agglomerates must be mi-
ery in the early twentieth century. In these application areas, nimised as much as possible to achieve optimal dispersion.
polymer compounding and polymer additives have been Aggregation may have serious adverse effects in different appli-
one of the key technologies to create value-added products. cations because the degree of separation of pigment particles can
One of the most striking advantages of polymeric materials decrease colour yield. The theory of pigment dispersion is the
is their easy colouring and the availability of endless colour mechanism of breaking up agglomerates into primary particles
combinations. and the stability of these newly formed particles.3 The specific
For colouring polymers, masterbatches are often used. process of dispersion of the pigment in the resin can be divided
Plastic materials with specific levels of certain processing into three steps as follows. The first step is that the molten wax
agents and certain pigments are combined for the preparation wets the pigment’s agglomerate surface, then infiltrates into the
of masterbatches. To achieve good colour strength, the disper- internal pores. In the second step, agglomerates are separated by
sion of pigment is critical. The pigment dispersion depends on intrinsic shear force and interaction between the particles in the

Coloration Technology. 2020;136:1–9. wileyonlinelibrary.com/journal/cote © 2020 Society of Dyers and Colourists | 1


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| YÜCETÜRK and SEYdIBEYOĞLU

pigments. The final step is that the molten resin and wax wet the masterbatches, with a melt flow index (MFI) of 22 g/10 min-
newly formed particles and covers them until the agglomeration utes (190°C and 2.16 kg) and a melting temperature of
ends. This method is called the wetting process.4 105°C. According to the company's technical data sheet, the
Different types of waxes can be used in the wetting process. number average molecular weight (Mn), weight-average mo-
One of the most widely used wax types in the masterbatch in- lecular weight (Mw), and polydispersity index (PDI) values
dustry is polyethylene waxes. These waxes may be homopoly- of LDPE homopolymer were 29 600, 157 000 g/mol, and 5.3,
mers, where the polymer chain is based upon one monomer respectively. The blue pigments with colour index number
unit, such as ethylene, or they may be copolymers, based upon PB15:1, K6902 from BASF (Ludwigshafen, Germany), and
two or more units, such as ethylene and vinyl acetate. These BK828 from Meghmani Organics Ltd (Ahmedabad, India)
types of modified polymer materials contain beneficial adhe- were used. During the experiments, four types of waxes were
sive additives, as they often include polar and non-polar groups used. All waxes, Luwax A (ethylene homopolymer wax),
together on the same molecule, which can function together in Luwax EVA 3 (ethylene copolymer wax), Luwax AF 31
the mixture for stability and adhesion.5,6 Another type of wax (micronised polyethylene wax), and Luwax OA 5 (oxidised
is oxidised polyethylene wax, which is produced by mild air polyethylene wax) were supplied from BASF.
oxidation of polyethylene. It is a polar one, used to prepare
emulsions with various products to improve the quality and per-
formance of the end product.7,8 The particle sizes of waxes are 2.2 | Scanning electron microscopy
generally between 500 and 2000 µm. Particularly when com-
pared to organic pigments, which are between 2 µm and a maxi- Examination of the morphology and distribution of the pig-
mum of 100 µm in size, standard wax particles are much larger. ments and the tensile test specimens were performed by Zeiss
Micronised waxes have an average particle size of between 5 Sigma 300 VP-FESEM scanning electron microscope. The
and 30 µm. This property has a positive effect on pigment dis- samples were coated with gold and images were taken at an ac-
persion during production and processing.9 celerated voltage set to 5 kV. Energy dispersive X-ray (EDX)
Copper phthalocyanine alpha blue (CI Pigment Blue 15:1) analysis was also performed for elemental composition.
is used mainly as a pigment in the masterbatch industry. Its
brilliant blue colour, hiding strength, heat-resistance, weather
resistance, tolerance to the effect of alkali and acids are the 2.3 | Pigment particle size analysis
reason for the widespread use of these pigments.10
In this study, detailed parametric research conducted on Particle sizes of two different pigment samples were meas-
pigment stabilisation, and the effect of different wax types ured with the Horiba LA 350 particle size analyser using ISO
and different pigment grades on the masterbatch dispersion 13320 standard.11
level was investigated. In a laboratory type extruder, widely
used four types of waxes in the masterbatch industry, and
copper phthalocyanine alpha pigments in two different qual- 2.4 | Masterbatch production
ities were mixed with polyethylene matrix and converted
into masterbatches. Mechanical tests, colour comparison Masterbatches were produced using a co-rotating twin-screw
tests, and filter tests were carried out on the masterbatches. extruder LTE-20-44 (Labtech Engineering, Samut Prakan,
Extensive work has been done in the characterisation of pig- Thailand) having a screw diameter of 20 mm and a barrel length
ment dispersion using scanning electron microscopy (SEM). of 880 mm (length/diameter [L/D] = 44). Both pigments were
Masterbatch formulations are often kept secret in the indus- formulated with four different waxes in separate combinations
try, and information on formulations is very limited in the (Table 1). Matrix polymer and other ingredients were mixed
scientific community. Therefore, in this study, we aimed to for 10 minutes in a benchtop high-speed mixer at 2000 rpm.
explain some critical details about the stability of pigments The mixture was fed by the hopper of the extruder with 20 rpm
and characterisation of masterbatches. and the main screw speed was 190 rpm. The zone temperatures
of the extruder were in the range of 140 to 170°C. After the
masterbatches were produced, they were dried at 80 ± 2°C for
2 | E X P ER IME N TA L 1 hour and the moisture they held was removed.

2.1 | Materials
2.5 | Measurement of the quality of dispersion
The base polymer low-density polyethylene (LDPE) was
supplied from Petkim Petrochemical Company (Izmir, To quantify the dispersion, a filter test machine LE20-30/P
Turkey). Petilen I22-19T was used as a matrix material in (Labtech Engineering) having a screw diameter of 20 mm
YÜCETÜRK and SEYdIBEYOĞLU
| 3

was used. The tests were carried out using 15 μm filters, ac- Laboratory Press (Labtech Engineering), which has heating
cording to ISO 23900-5:2015.12 and cooling platens. Tensile test samples were prepared using
Type 1 mould according to the ASTM D638-14 standard.13

2.6 | Preparation of plates


2.7 | Colour measurement
Melt mixing of the pellets was prepared using a Gelimat, a
high-speed laboratory thermokinetic mixer. Each full-colour For full shade colour and colour strength measurements of
shade plate was made from mixing of 0.5 g masterbatch and masterbatches, the X-Rite Ci64 spectrophotometer was used.
49.5 g LDPE for 15 to 20 seconds at 2000 rpm. To measure The spectrophotometer has a spherical light source to meas-
the colour strength, white masterbatches containing 50% tita- ure the colour of rough surfaces of plastic parts accurately.14
nium dioxide supplied from Budin Kimyevi Maddeler (Izmir, Measurements were made in the CIELab D65/10° colour sys-
Turkey) were mixed with blue masterbatches using the same tem, according to ASTM E308-18 standard.15
process. At this point, titanium dioxide and pigment in a ratio
of 10:1 were used in the mixture. For this, a formula contain-
ing 0.4 g of blue masterbatch, 2 g of white masterbatch, and 2.8 | Tensile test
47.6 g of LDPE was used. After heating the hot press until
processing temperature (140°C), produced mixtures were The mechanical properties of samples were tested by a
placed into the 2 mm thick mould cavity (15 cm × 15 cm). Shimadzu AGS-X tensile tester machine with a 5 kN load
Plates were obtained from the mixture by using a Hydraulic cell and a testing speed of 50 mm/min.

TABLE 1 Formulations of masterbatches

BASF Meghmani Luwax A Luwax EVA Luwax AF Luwax OA Polyethylene


Masterbatch codes K6902 (g) BK828 (g) (g) 3 (g) 31 (g) 5 (g) (g)
MB1 250 — — — — — 750
MB2 — 250 — — — — 750
MB3 250 — 150 — — — 600
MB4 250 — — 150 — — 600
MB5 250 — — — 150 — 600
MB6 250 — — — — 150 600
MB7 — 250 150 — — — 600
MB8 — 250 — 150 — — 600
MB9 — 250 — — 150 — 600
MB10 — 250 — — — 150 600

10 µm EHT = 5.00 kV Signal A = SE2 Date:15 Apr 2019 10 µm EHT = 5.00 kV Signal A = SE2 Date:15 Apr 2019
WD = 7.5 mm Mag = 2.50 KX Time:11:24:53 WD = 8.5 mm Mag = 2.50 KX Time:11:17:07

FIGURE 1 BASF K6902 (left), Meghmani BK828 (right)


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| YÜCETÜRK and SEYdIBEYOĞLU

2.9 | Preparation of plastic films 3 | RESULTS AND DISCUSSION

The masterbatch and polyethylene blends were made into a 3.1 | Pigment analysis
thin film by a blown film machine (Adali Machine), which
has a 35 mm screw size. To obtain film samples, a 4:1 blow- 3.1.1 | Scanning electron microscopy
up ratio (bur) was used. Briefly, 40 g of masterbatches were
mixed with 960 g of film type polyethylene (Petilen F2-12), In the SEM-analysis of pigments (Figure 1), it was seen
and 120 μ films were produced at 150°C. During and after the that the distribution of BASF K6902 was more homog-
process, agglomerated particles of pigments on the surface enous, and the agglomeration was lower than Meghmani
and inside the films were visually inspected. BK828.
Carbon, copper, and nitrogen elements, in the molecular
structure of the pigment, were found in the EDX analysis.
TABLE 2 Elemental composition of BASF K6902
A certain amount of oxygen was found in both pigments. In
Element Weight (%) Atomic (%) BASF K6902, a low amount of sodium and chlorine elements
Carbon 50.05 59.02 were also found (Table 2).
Nitrogen 25.59 25.88 Higher amounts of nitrogen and lower amounts of oxygen
were found in the Meghmani BK828 pigment. Also, trace
Oxygen 13.77 12.19
amounts of sodium and chlorine in BASF K6902 were not
Sodium 0.73 0.45
found in this pigment (Table 3).
Chlorine 1.46 0.58
The source of these trace elements is probably related to
Copper 8.39 1.87 sodium chloride used during the pigment production pro-
cess. Phthalocyanines must undergo some sort of particle
size reduction by salt milling to achieve better dispersion.
The grinding operation is performed with sodium chloride or
TABLE 3 Elemental composition of Meghmani BK828 other salts at room temperature and in the presence of certain
Element Weight (%) Atomic (%) specified organic solvents.16
After grinding, small amounts of salt can be present with-
Carbon 51.16 59.62
out having a detrimental effect on the process or final pig-
Nitrogen 33.24 33.21
mentary properties. The amount of salt that can be tolerated
Oxygen 5.70 4.98
will depend upon the nature of the salt and the process in
Copper 9.91 2.18 which it is present.17,18

7.0 100
6.0 90
80

Under Size, %
5.0 70
4.0 60
q, %

50
3.0 40
2.0 30
20
1.0 10
0.0 0
F I G U R E 2 Particle size distribution of 0.010 0.100 1.000 10.00 100.0 1000 3000
Meghmani BK828 Diameter, µm

10 100
9 90
8 80
Under Size, %

7 70
6 60
q, %

5 50
4 40
3 30
2 20
1 10
FIGURE 3 Particle size distribution of 0 0
BASF K6902 0.010 0.100 1.000 10.00 100.0 1000 3000
Diameter, µm
YÜCETÜRK and SEYdIBEYOĞLU
| 5

3.1.2 | Particle analysis of pigments 140

120 115
Particle sizes of the Meghmani BK828 (Figure 2) and BASF 105
100
K6902 (Figure 3) pigments were measured with blue laser 100 95

Color Strenght, %
light using a wet process. According to the histograms, the
particle size distribution of BASF K6902 pigment was more 80
homogeneous than Meghmani BK828.
60
While the BASF pigment only had a slightly smaller par-
ticle size in terms of both mean and median values (Table 4), 40
significant differences in the dispersion results were observed
between the two pigment samples (Figure 4). 20

0
MB1 MB2 MB5 MB9
3.2 | Masterbatch analysis Masterbatch Codes

3.2.1 | Filter pressure tests of masterbatches FIGURE 5 Colour strength of masterbatches

Fifteen micrometer filters were used during the filter tests.


The MB1 and MB2 results were as high as we expected. 180
157.6
Similar results on dispersion quality without using wax was 160
146.6
reported by Lahcen Safraoui et al.19 However, in some cases, 140
125.2
worse filter test results were obtained with wax-containing
Elastic Modulus, MPa

120 113.5
masterbatches during our study. Also, generally higher re-
sults were obtained in experiments with Meghmani pig- 100
ment. This was because the pigment particle distribution of 80
Meghmani was less homogeneous than BASF pigment. The
60
wax particles in the BASF pigment fulfilled the wetting task
40

TABLE 4 Particle sizes of pigments 20

Pigment Mean size (μm) Median size (μm) 0


MB1 MB2 MB5 MB9
BASF K6902 9.52 12.27 Masterbatch Codes
Meghmani BK828 10.55 13.24
FIGURE 6 Elastic modulus of masterbatches

14 12
11
12 11.84
11.04 10 9.3 9.3
9.0
Filter Pressure Value, bar/g

9 8.7
Maximum Stress, MPa

10
8.96 8
8 7.76 7.68 7
6
6 5.36 5

3.92 4
4 3.52
3.12 3

2 2
0.88 1
0 0
MB1 MB2 MB3 MB4 MB5 MB6 MB7 MB8 MB9 MB10 MB1 MB2 MB5 MB9
Masterbatch Codes Masterbatch Codes

FIGURE 4 Filter pressure values of masterbatches FIGURE 7 Maximum stress of masterbatches


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| YÜCETÜRK and SEYdIBEYOĞLU

more successfully. On the contrary, sufficient wetting was need for higher power and shear in the extruder. Since all
not achieved in Meghmani. The weakening of the interfacial masterbatches were produced with the same extruder param-
interactions between polymer and pigment resulted in the eters, the shear was insufficient in masterbatches made with
Meghmani pigment. This, combined with the incompatibil-
110 ity of the wax type, resulted in a comparatively inadequate
100 87.7
dispersion.20
90 81.3
For BASF K6902 and Meghmani BK828, the best filter
80 pressure values (MB5 and MB9) were obtained with a mix-
Strain at Break, %

70
ture of micronised wax. As a result, no wax had a distinct
advantage, except for micronised wax (Figure 4).
60
In the later stages of the study, MB1 and MB2 masterbatches
50
prepared without wax were used as standard, and these master-
40
batches were compared with MB5 and MB9 masterbatches, in
30
which the best results from filter tests were measured.
20 11.9
9.5
10
0 3.2.2 | Colour strength measurement of
MB1 MB2 MB5 MB9 masterbatches
Masterbatch Codes

FIGURE 8 Strain at break of masterbatches The pigment concentration of masterbatches was reduced to
0.2% in LDPE. Relative colour strength was calculated by

100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.9 mm Mag = 100 X Time:14:11:51 WD = 10.2 mm Mag = 100 X Time:14:16:19

100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.3 mm Mag = 100 X Time:14:18:25 WD = 10.3 mm Mag = 100 x Time:14:20:45

F I G U R E 9 Fractographic studies of tensile test samples with 100× magnification are MB1 (top left), MB2 (top right), MB5 (bottom left),
MB9 (bottom right)
YÜCETÜRK and SEYdIBEYOĞLU
| 7

measuring each sample five times with a spectrophotometer increase in elastic modulus. This was observed with higher
(Figure 5). melting enthalpies in wax-containing blends.22
It was concluded that MB5 and MB9 samples dispersed With the addition of wax, the proportion of polyethylene in
with micronised wax yielded more colour strengths than the formula was reduced. This resulted in increased brittleness
MB1 and MB2 masterbatches without wax in their formu- of samples and reduced elongation (Figure 8). It is explained
las. This result agrees with the results obtained in the filter by Luyt et al.23 that stress is a function of crystallinity, and a
test. Increased pigment dispersion, resulted in a significant decrease in stress is expected with an increase in LDPE content.
decrease in the filter pressure value (FPV) and an increase in The appreciably higher modulus in the samples with higher wax
the relative colour strength.21 content and relatively low LDPE content is also related to the
lower tie-chain fraction that gives rise to more brittle samples.

3.2.3 | Tensile test of masterbatches


3.2.4 | Fractographic studies
It was seen that both the elastic modulus and tensile strengths
of MB5 and MB9 were higher than MB1 and MB2 (Figures 6 The SEM images taken from the fractured parts of the ten-
and 7). The mechanical strength of masterbatches improved sile test samples at 100× magnification showed that the
with increased wax usage. This was because the blends were surface morphologies of MB1 and MB2 with higher poly-
of higher crystallinity compared to pure polyethylene. The ethylene content were ductile. However, MB5 and MB9
short and liner chains of the wax molecules caused an in- with low polyethylene content were found fragile. While
crease in crystallisation in the mixture and a significant larger pigment particles were seen on MB1 and MB2

20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
ED = 12.0 mm Mag = 1.00 KX Time:14:13:36 WD = 10.2 mm Mag = 1.00 KX Time:14:17:20

20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.3 mm Mag = 1.00 KX Time:14:19:52 WD = 11.0 mm Mag = 1.00 KX Time:14:21:51

F I G U R E 1 0 Fractographic study of tensile test samples with 1.00K× magnification are MB1 (top left), MB2 (top right), MB5 (bottom left),
MB9 (bottom right)
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| YÜCETÜRK and SEYdIBEYOĞLU

MB1 MB2 polyethylene wax types with two different phthalocyanine


alpha blue pigments. For this purpose, particle size distribu-
tion and morphological structure of the pigments were exam-
ined initially. Although there was no significant difference
in particle size analysis, the more homogeneous distribution
was found to affect the dispersion quality and better filter
test results were obtained. Due to the increased dispersion
quality, it has been observed that the masterbatch with the
best filter test result is also the masterbatch with the high-
MB5 MB9 est colour strength. These results were similarly observed
in the blown film process. It has been found that another
factor affecting the dispersion results is the type of wax.
Masterbatches made with micronised wax gave the best re-
sults in both pigments. It has been observed that the particle
size of the wax is more important than the chemical structure
of the wax in the dispersion process. The increasing disper-
sion also affected the results of the tensile tests. It was ob-
served that the masterbatches produced with micronised wax
had higher tensile strength and elastic modulus than those
FIGURE 11 Blown film samples of MB1, MB2, MB5, and MB9 without wax. The addition of wax increased crystallinity in
the polyethylene matrix, and therefore, the elastic modulus
and tensile strength of the samples increased. However, the
surfaces because of the lower dispersion quality of mas- fact that wax molecules were too short to form tie chains
terbatches, smaller particles were seen on the surfaces of caused a decrease in strain and increased brittleness.
MB5 and MB9 masterbatches which have better pigment The high colour strength, longer time filter clogging, and
distribution (Figure 9). high mechanical strength values obtained with micronised
At 1.00K× magnification, pigment particles could be seen wax are industrially satisfactory. Results may be the same for
in more detail, but no significant differences were observed different pigment types, but further studies are required to
compared to the filter test results. Pigment crystals were not confirm the statement.
only predominantly brick-shaped but also contained some ir-
regularly shaped particles. From the images, it was seen that ACKNOWLEDGEMENTS
the presence of solid pigment particles slightly disrupted the This study was supported by Budin Kimyevi Maddeler,
network structure of the polyethylene matrix (Figure 10). Cigli, Izmir, Turkey. The authors would like to thank
Similar results were also observed by different researchers Hakan Budin, Okan Budin, and the R&D team for their
with different types of pigments and polymers.24 support.

ORCID
3.2.5 | Blown film samples of masterbatches Mert Yücetürk https://orcid.org/0000-0002-9692-0893

One hundred and twenty micrometer films produced with the R E F E R E NC E S


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